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TRANSCRIPT
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TECHNISCHE UNIVERSITÄT MÜNCHEN LEHRSTUHL UND PRÜFAMT FÜR VERKEHRSWEGEBAU
Univ. Prof. Dr.-Ing. S. Freudenstein
Report No. 2466 of 19th of September 2008
RESEARCH REPORT
Investigation on FFU synthetic wood sleeper
(Komat GmbH, Austria)
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Lehrstuhl und Prüfamt für Verkehrswegebau der TU München, Bericht Nr. 2466
Research Report No. 2466
Investigation on FFU synthetic wood sleeper
(Fa. Komat GmbH, Austria)
Dieser Bericht ist die englische Fassung des Originalberichtes in deutscher Sprache. Im Zweifel hat die deutsche
Fassung Gültigkeit.
This is the english version of the original report in german language. In doupt the german version is valid.
1. GENERAL
By order of company Komat GMBH, Austria, extensive tests on SEKISUI FFU-synthetic
wood sleepers (Eslon Neo Lumber) for railway construction had to be performed.
According to client statement, glass fibre strands get aligned and cast-in with polyurethane in
the manufacturing process of the sleepers. After curing, the sleepers will be cut to millimetre
precision.
Based on consultation with EBA (German Railway Authority), following test program was
executed:
- Behaviour of the sleeper in repeated load test (fatigue test) under vertical and
horizontal dynamic load. Bearing of the sleeper on ballast in accordance with DIN EN
13481-3 (Requirements for fastening systems on wooden sleepers).
- Sleeper screw piecing test to determine the tensile force in the screw depending on
torque moment.
- Pull-out test on sleeper screws according to DIN EN 13481-2.
- Impact load test to simulate derailment according to DB-Standard (technical delivery
terms)
- Electrical resistance test according to DIN EN 13146-5.
- Static and dynamic test on the sleepers according to DIN EN 13230-2.
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Lehrstuhl und Prüfamt für Verkehrswegebau der TU München, Bericht Nr. 2466
In total 20 sleepers (in raw condition, without any drillings for screws) were delivered by the
client. The dimensions of these sleepers (26 x 16 x 260 cm) are equal to conventional
wooden sleepers. See appendix 1 for a drawing of the fastening system of the sleeper.
For execution of the tests with fastenings, six of the delivered sleepers were drilled for the
sleeper screws by the client, as follows:
- Drilling diameter for sleeper screws: 19mm
- Widening of the holes in the upper 25 mm to a diameter of 24 mm.
- Depth of drilling: 14,5 cm
- The sleeper screws were torqued to a moment of 220 Nm. In advance, vaseline was
applied into the drilling holes.
2. TEST EXECUTION 2.1 Repeated load test accorsing to DIN EN 13146-3 (February 2003) on sleeper No. 6 For appointment of the test loads in the fatigue test, the dynamic stiffness of the rail pad has
to be determined in advance according to appendix B of DIN EN 13481-3. The dynamic
stiffness between 20 kN and 95 kN at a load frequency of 5 Hz is higher than 200 kN/mm.
With a dynamic stiffness > 200 kN/mm the rail pad is classified “stiff”. (On the secure side,
the elasticity of the sleeper is not taken into account!)
Based on the dynamic stiffness the test load and position derive from table 2 of DIN EN
13481-3. The test parameters for one fastening system are as follows:
Upper load: Pv/cos α = 83 kN
Angle of Inclination of load: α = 33°
The head of the rail has to be milled for the test to a milling value of X = 50 mm. The test setup is in accordance to figure 3b of DIN EN 13146-4 (see pictures in attachment
1.1).
Executing the test on two fastening systems (one complete sleeper), the upper load in the
test is 2 x Pv = 140 kN and the lower load is 10 kN at a load frequency of 3 Hz. According to
table 1 of DIN EN 13481-3 the in-situ reference values, simulated by the repeated load test
over 3 million load cycles at a load frequency of 3 Hz, are 225 kN axle load and a curve
radius of the railtrack >150m.
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The Appendices 2a to 2d show the deflections of the fastening within the test. Measurement
of the displacements was done by dial gauges according to figure 5 of DIN EN 13146-4. The
standards DIN EN 13481-3 and DIN EN 13146-4 define no requirements regarding the
displacements and deflections in the fatigue test. See table 1 of this report for determined
horizontal railhead displacement under load after the fatigue test. Table 1: resilient railhead displacement permanent railhead displacement
fatigue test right fastening left fastening right fastening left fastening After 3 million load
cycles 2.12 mm 1.71 mm 0.42 mm 0.29 mm
According to existing experiences the shown values are within the permissible range.
Additionally the horizontal and vertical movement of the base plate (fieldside) was measured
to a resilient vertical deformation of 0.23 mm respectively a permanent vertical deformation
of 0.14 mm towards the sleeper. Horizontal movement of the base plate was 0.2mm on
average.
Visual detection of the bottom side of the sleeper after removing from the ballast showed
only marginal pressure marks on the bottom.
An additional test phase with increased temperature of 48°C was executed on the same
sleeper and fastening. Within 1.28 million load cycles displacements occurred as shown in
table 2. The appendices 3a to d show the recorded deflections during the test at T = 48°C. Table 2: resilient railhead displacement permanent railhead displacement
fatigue test right fastening left fastening right fastening left fastening After 1.28 million load
cycles 2.05 mm 1.93 mm 0.41 mm 0.48 mm
Values in table 2 are in the same range as in the fatigue test at ambient temperature (table
1). It can therefore be inferred that the mechanical behaviour of the system is only marginally
affected by increased temperature. After the test, the base plates were removed and
fastening torque was determined again (M = 180 Nm, average values of 8 Schrauben). The
upper surface of the sleeper showed an impression of the base plate (see photo in
attachment 1.2) with permanent deformations of 0.7 mm (fieldside of the rail), respectively
0.3 mm (in-side of the rail). The bottom side of the sleeper showed only light pressure marks.
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2.2 Tensile force in the sleeper screws in relation to torque moment and time
For this test recesses for application of strain gauges were milled into the shaft of two
sleeper screws on two opposite sides. Subsequently, the sleeper screws were calibrated in a
centric pull-out test device in order to get a correlation between tensile force and strain of the
screw.
The base plate was mounted onto sleeper no. 7, a torque moment of 200 Nm and
respectively 250 Nm was applied in steps (see photos in attachment 2).
Please see summarized results in table 3. Tabelle 3:
First test Second test
Torque
moment
Resting time Tensile force Resting time Tensile force
200 Nm t = o 17 – 21 kN t = o 21 kN
200 Nm t = 40 min 16 – 17 kN t = 40 min 18 kN
250 Nm t = o 25 kN t = o 25 kN
250 Nm t = 40 min 20 kN t = 40 min 22 kN
250 Nm t = 16 h 19 kN t = 3 days 20 kN
2.3 Pull-out test During pull-out test, a centric tensile force is applied to sleeper screws and measured by an
interconnected load cell (see photos attachment 2). Tests were conducted based on DIN EN
13481-2, attachment A, on all eight sleeper screw drillings of one synthetic sleeper (no. 5). Load was increased continuously until the screw was pulled out. Please see table 4 for the
recorded maximum pull-out force.
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Lehrstuhl und Prüfamt für Verkehrswegebau der TU München, Bericht Nr. 2466
Table 4:
Test No. Pull-out force [kN]
1 73,4
2 71,3
3 72
4 60
5 60
6 50
7 47
8 60
Average pull-out force is 61 kN. Previous pull-out tests on sleeper screws on wooden
sleepers showed pull-out forces of approx. 35 kN [Research Report No. 1687, dated June
30.,1997, not released].
2.4 Impact test / Derailment test
Sleeper derailment resistance is checked through an impact load test in accordance with DB
TL (German Railway technical delivery specifications for concrete sleepers – Basic Guideline
for Dimensioning, Construction and Approval Procedures). Each test sleeper has to be
subjected to impact load test I and II. A tup (dead weight 5 kN) with a wheel-flange shaped
blade is dropped twice per test from a height of 75 cm onto the impact position indicated
below on the edge of the sleeper. The sleeper is positioned at a slope of 30°. During testing,
the sleeper is placed on a 6mm elastic pad.
Impact test I / Derailment test I: Impact position 25 cm from center of rail, positioned towards sleeper center.
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Impact test I / Derailment test II: Impact position at 15 cm distance to sleeper edge.
Three sleepers without drilling holes were subjected to impact testing (number S7, S8 und
S9). The absence of the drillings does not affect the test results (impact load is not applied at
fastening positions). Please see attachments 3.1 to 3.5 for photo documentation. The tested
sleepers show no warping caused by impact. Damages in impact test I are limited to a small
area near impact position, in impact test II fibres were detached up to sleeper front end.
In impact test I (25 cm from central fastening positioned towards sleeper center) fibres at
impact area are merely cut through to a depth of 25 mm. Surface deformation at impact area
in the shape of a wheel flange (resp. the edge of the impact tub). Length of surface
indentation is approx. 90 mm at most. Behaviour is comparable to that of wooden sleepers.
In impact test II a wedge-shaped cutout (15 cm distance from sleeper front end) is removed
from the sleeper. The dimensions of the cutout piece match the length of the surface
indentation (70 to 90 mm). The horizontal crack runs from the point of impact to the front end
of the sleeper (length: 15 cm).
In service, sleepers are not treated by bending in the area of the wedge-shaped cutout.
Consequently, the reduction in diameter in this area has no effect on sleeper bending
behaviour.
Prior to and after each applied impact, each sleeper was checked for deformation with a
graduated measuring rod. A change in track gauge (test criterion) can solely occur as a
consequence of permanent sleeper deformation. The sleepers did not show any rotation or
warping. Thus, track gauge remained constant.
An additional requirement of this test is, to show only sporadic continuous cracks (transverse
to sleeper direction) and scattered spalling down to the reinforcement as a result of impact
load (as mentioned previously, the above specification applies to concrete sleepers). Cause
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of the fact, that the synthetic wood sleeper does not feature any reinforcement, these criteria
cannot be applied.
In accordance with the avertable evaluation criteria, sleeper function (load capacity and track
gauge) remained unaffected. The horizontal crack inflicted by impact test II invariably ran
from the point of impact to the front end of the sleeper, but never to the rail fastenings.
Therefore, it can be expected that the base plate screw connections are not affected by any
such load.
2.5 Determination of the electrical resistance between the rails (DIN EN 13146-5) As in all further tests, the base plate of this “KS-fastening” is mounted onto the sleeper
without a plastic pad below. Before setting sleeper screws, vaseline is applied to dowel
holes. The fastener is set to an air gap of 1.0mm between the center loop of the fastening
clip and the rail foot.
The standard DIN EN 13146-5 “Determination of electrical resistance” demands to calculate the electrical resistance as mean value of three measurements. Within this test, the electrical
resistance between two short lengths of a rail (approx. 0,5 m, type 60E1), fixed on the
sleeper by the fastening components, has to be measured, while the whole sleeper and
fastenings are sprayed with water at a controlled rate of 7 ±1 l/min from each of 4 nozzles for
2 minutes. By the correction factor Kγ the conductivity of the used water is taken into account.
The conductivity γ [mS/m] of the water shall be between 20 and 80 mS/m. It has to be
measured and corrected to a temperature of 25 °C. The test stand is compliant to figure 2 in
EN 13146-5.
During the test (Duration: 15 minutes) the sleeper is insulated to the ground. An alternating
voltage of 30 V AC and 50 Hz, which is impressed on the two rails, and the resultant current
flow will be recorded (device: bmc PCI-Base 300).
By the correlation R = U/I the minimum electrical resistance Rγ between the two rails will be
evaluated. The corrected resistance will be calculated by the following equation:
R33 = Rγ * Kγ
with Kγ = 0,03 * γ
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Lehrstuhl und Prüfamt für Verkehrswegebau der TU München, Bericht Nr. 2466
The specification demands a minimum electrical resistance of 5 kΩ as mean value of three
measurements. Table 5 shows the results of the test. See appendix 4 for the recordings of
the test. Table 5: Electrical resistance of the synthetic wood sleeper with KS-fastening
Test 1 Test 2 Test 3
Date 10.07.2008 11.07.2008 12.07.2008
Rγ [kΩ] 38,9 63,8 57,7
γ [mS/m] 44,4 45,3 44,6
Kγ 1,332 1,359 1,338
R33 [kΩ] 51,8 86,7 77,2
Mean value R 33 [kΩ] 71,9
Hence, the requirement of EN 13481-5 has been easily met.
2.6 Static test in sleeper center (Sleeper No. 1)
In order to investigate sleeper behaviour when subjected to bending load, a static test was
conducted on the center of the sleeper on the basis of DIN EN 13230-2.
Test setup is shown in attachment 4. Bearings clearance was 1.5 m, load plate width was
100 mm. The initial test load was set to 20 kN. Subsequently, the load was increased in
steps of 5 kN, while sleeper bending was registered by four dial gauges. Appendix 5 shows
the values of sleeper bending up to a load of 135 kN, corresponding to a torque moment of
47 kNm. Based on the measured bending value the Young’s Modulus E was determined
using the following equation:
fI48lPE3
⋅⋅⋅
= .
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Lehrstuhl und Prüfamt für Verkehrswegebau der TU München, Bericht Nr. 2466
E = Young’s Modulus E N/mm²
l = Bearings clearance: 1500 mm
I = Torque of Inertia [mm4]
f = Bending deflection under load [mm]
Thus, Young’s Modulus E of the synthetic wood sleeper under bending load is approx.
7000 N/mm².
Up to a load of 240 kN, corresponding to a bending tensile strength of 74 N/mm² on the
bottom of the sleeper, no crack was detected within the bending tensile area. Strong plastic
deformations and superficial fissures were detected within the bending pressure area (upper
side of the sleeper), although it must be noted that generally, deformations of this scope do
not occur in service.
The same test (265 mm x 160 mm) was conducted concurrently with a wooden sleeper
(beechwood 265 mm x 160 mm). Please see results in appendix 5. According to the test
results, the wooden sleeper failed at a load of 80 kN within the bending tensile area.
2.7 Fatigue test in sleeper center (sleeper No. 2)
In order to investigate the behaviour of the synthetic sleeper under repeated load, a fatigue
test according to DIN EN 13230-4 was conducted. Please see the picture in attachment 5 for
the test setup. During the entire testing procedure, sleeper bending and strain on the bottom
side of the sleeper in the area of maximum torque moment were registered.
The bearings clearance was 1.5 m during testing, load application was carried out according
to DIN EN 13230-4 using a load application hinge with width 100 mm.
Load was applied up to 100 kN. Subsequently, the fatigue test was conducted with the
following basic conditions:
Upper test load Po = 86 kN
Lower test load Pu = 21.5 kN
Frequency f = 2 Hz.
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The upper load corresponds to a torque moment of 30 kNm. This value is consistent with the
test torque for switch sleepers in accordance with DBS 918 143. This means, that the test
conditions were extremely critical
During fatigue testing with 2.5 million load cycles no damages were detected on the sleeper.
Appendix 6 shows deflection prior to the fatigue test and after 2.5 million load applications.
Thus, resilient deflection after 2.5 million loads is only 0.4mm greater than at the start of the
test.
Appendix 7 shows deformations through static load during the fatigue test. It was observed
that during the entire testing procedure, deformation remained nearly constant, this means
that there were no visible signs of fatigue. Measured strains on the bottom side did not vary
after 2.5 million load cycles. Finally, the sleeper was subjected to a load of 175 kN,
corresponding to a bending tensile stress of 56 N/mm², whereat no cracks appeared in the
tensile area (bottom side). Plastic deformations were visible in the compression area (upper
side).
2.8 Fatigue test on rail seat (sleeper No. 4)
According to test 2.7, there is no failure due to high bending tensile stresses. The fatigue test
on rail seat (compression load) was supposed to indicate sleeper behaviour under high
pressure.
The fatigue pressure test on the rail seat was conducted according to DIN EN 13230-2
(concrete sleepers). According to the standard, a bearings clearance of 600 mm was
selected. Load application took place over the base plate with completely mounted rail
fastenings. An upper load of 150 kN was selected for the fatigue test. Therefore, testing
procedures also incorporated the most severe conditions, such as incorrect track setting,
inaccurate load distribution of the rail, stiff bearings and a high dynamic allowance to an axle
load of 250kNm.
Please see attachment 6 for a photo of the test setup. The test was conducted under the
following basic conditions:
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Lehrstuhl und Prüfamt für Verkehrswegebau der TU München, Bericht Nr. 2466
Upper test load Po = 150 kN
Lower test load Pu = 30 kN
Frequency f = 5 Hz.
During fatigue testing with 2.0 million load cycles, no damages were detected on the sleeper.
Appendix 8 shows bending prior to and after the fatigue test. Therefore resilient bending
(after 2 million load cycles) is 0.2 mm higher than before the start of the test.
Subsequently, the base plate was removed. On the surface of the sleeper (below base plate)
permanent deformations of approx. 1.0 mm were detected. No further damages were
noticed.
2.9 Static pressure test (on second railseat of sleeper No. 4)
In order to analyze sleeper behaviour under vertical load, the sleeper was installed on an
even surface, then vertical pressure was applied onto the completely mounted fastening
system. Up to a load of 150 kN no permanent deformation was detected. Appendix 9 shows
permanent deformation and corresponding load in the fastening system.
Thus, a load of 300 kN (on one rail seat) causes permanent deformation of a maximum of
0.8 mm below the base plate (see photos in attachment 7). As pointed out in 2.8, the load on
one rail seat by an axle load of 250 kN is 150 kN in case of most severe conditions.
2.10 Static bending of sleeper at ambient temperature and at T = -10°C
Both tests were conducted with a bearings clearance of 1.0 m. For the test at temperature
below zero, the sleepers were stored in a climate-controlled environment at T= -20°C for two
days. During testing, sleeper temperature was checked via a 5cm deep drillinghole placed on
the face side of the sleeper. Between removal of the sleeper from the climate–controlled
environment and the test execution, the sleeper was warming up caused by an ambient
temperature (RT) of about + 23°C. The average temperature of the sleeper whilst test
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execution (during three static load cycles with recurrent dial gauge readings) is therefore
indicated at T = -10°C .
Appendix 10 shows the deflection of sleeper No. 3 at T = RT by loading up to 200 kN
(bearings clearance: 1,0 m).
Appendix 11 (sleeper No. 11) demonstrates bending at test temperature T = -10°C and
otherwise ancillary conditions.
Test results confirm that deformation behaviour under applied bending moment is only
marginal dependent on temperature. The sleeper shows no signs of embrittlement at low
temperatures. A comparison of deformation in the first and third load cycles does not show
any significant differences. This leads to the conclusion that fibres will not break when
subjected to the applied bending moment - even at low temperatures.
3. SUMMARY
The company Komat GmbH, Austria, ordered extensive testing of the Sekisui FFU synthetic wood sleeper (Eslon Neo Lumber) for application in rail tracks. According to client statement,
glass fibre strands get aligned and cast-in with polyurethane in the manufacturing process of
the sleepers. After curing, the sleepers will be cut to millimetre precision.
Based on consultation with EBA (German Railway Authority), following test program was
executed:
- Behaviour of the sleeper in repeated load test (fatigue test) under vertical and
horizontal dynamic load. Bearing of the sleeper on ballast in accordance with DIN EN
13481-3 (Requirements for fastening systems on wooden sleepers).
- Sleeper screw piecing test to determine the tensile force in the screw depending on
torque moment.
- Pull-out test on sleeper screws according to DIN EN 13481-2.
- Impact load test to simulate derailment according to DB-Standard (technical delivery
terms)
- Electrical resistance test according to DIN EN 13146-5.
- Static and dynamic test on the sleepers according to DIN EN 13230-2 (standard for
concrete sleepers).
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During fatigue test (effect of repeated loading -chapter 2.1) at T = RT (ambient temperature)
und T = +48°C no significant damages to sleeper or fastenings were detected.
The tensile force of the sleeper screws (chapter 2.2) against an externally applied pulling
force only decreased marginally during a longer time span.
Sleeper screw pull-out load (chapter 2.3) showed higher values than those recorded in
previous tests on wooden sleepers.
German Railway technical delivery specifications for concrete sleepers – Basic Guideline for
Dimensioning, Construction and Approval Procedures
In impact test (chapter 2.4) in accordance with the technical delivery specifications of DB
„German Railway technical delivery specifications for concrete sleepers – Basic Guideline for
Dimensioning, Construction and Approval Procedures“, the sleeper merely showed a limited
indentation caused by the impact test I (impulse in-side the rail). After impact test II (impulse
fieldside of the rail) there was some chipping along the edge congruent with the depth of the
indentation. Sleepers did not get warped as a result of impact testing, as the track gauge
remained constant.
Electrical resistance between the rails (chapter 2.5), tested in accordance with DIN EN
13146-5, shows a markedly higher value of more than 70 kΩ. This result is very likely to
comply to the required minimum resistance of 5 kΩ.
Bending test results (chapter 2.6 to 2.8) showed a very high bending tensile strength. The
mechanical behaviour and the weight of the synthetic wood sleeper is identical to that of a
regular wooden sleeper. Bending stiffness is higher than that of the classic beech sleeper,
while bending tensile strength is significant higher. Therefore, the sleeper is able to resist to
a significantly greater amount of resilient deformation without damages in shape of cracking.
During static pressure test (chapter 2.9), with applied load to the rail fastening on a rigid
bedded sleeper, no plastic deformations of the sleeper surface were detected up to a vertical
load on one rail seat of 150kN (maximal value for an axle load of 250 kN under most severe
conditions).
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Appendix 2 aReport 2466
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ad b
efor
e fa
tigue
test
0123456
020
4060
8010
012
014
0
Load
[kN
]
Horizontal deflection [mm]ra
il he
adra
il fo
ot
Fat
igue
test
at a
mbi
ent t
empe
ratu
reon
left
rail
seat
050
0000
1000
000
1500
000
2000
000
2500
000
3000
000
Load
cyc
les
(LC
)
rail
head
at u
pper
load
rail
head
at l
ower
load
rail
foot
at u
pper
load
rail
foot
at l
ower
load
stat
ic lo
ad a
fter f
atig
ue te
st
020
4060
8010
012
014
0
Load
[kN
]
rail
head
rail
foot
Am
plitu
de o
f osc
illat
ion
Per
man
ent d
efle
ctio
n of
rail
head
afte
r dis
char
ge (P
= 0
kN):
0,
06 m
m
Per
man
ent d
efle
ctio
n of
rail
head
afte
r dis
char
ge (P
=
0kN
): 0
,29
mm
Per
man
ent d
efle
ctio
n of
rail
foot
afte
r dis
char
ge (P
= 0
kN):
0,
01 m
m
Per
man
ent d
efle
ctio
n of
rail
foot
afte
r dis
char
ge (P
= 0
kN):
0,
18 m
m
Am
plitu
de o
f osc
illat
ion
-
Appendix 2 b
Report 2466
stat
ic lo
ad b
efor
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tigue
test
01234
020
4060
8010
012
014
0
Load
(kN
)
Vertical Displacement (mm)
rail
foot
fiel
dsid
e
rail
foot
in-s
ide
Fat
igue
test
at a
mbi
ent t
empe
ratu
reon
left
rail
seat
050
0000
1000
000
1500
000
2000
000
2500
000
3000
000
Load
cyc
les
(LC
)
rail
foot
fiel
dsid
e at
upp
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load
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load
stat
ic lo
ad a
fter f
atig
ue te
st
020
4060
8010
012
014
0
Load
(kN
)
rail
foot
fiel
dsid
e
rail
foot
in-s
ide
Am
plitu
de o
f osc
illat
ion
Per
man
ent d
ispl
acem
ent o
n fie
ldsi
de a
fter d
isch
arge
(P =
0kN
):
0,2
2 m
m
Per
man
ent d
ispl
acem
ent o
n fie
ldsi
de a
fter d
isch
arge
(P =
0k
N):
0,0
2 m
m
Per
man
ent d
ispl
acem
ent o
n in
-sid
e af
ter d
isch
arge
(P =
0k
N):
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2 m
m
Per
man
ent d
ispl
acem
ent o
n in
-sid
e af
ter d
isch
arge
(P =
0k
N):
0,1
2 m
m
Am
plitu
de o
f osc
illat
ion
-
Appendix 2 cReport 2466
stat
ic lo
ad b
efor
e fa
tigue
test
0123456
020
4060
8010
012
014
0
Load
[kN
]
Horizontal deflection [mm]ra
il he
adra
il fo
ot
Fat
igue
test
at a
mbi
ent t
empe
ratu
reon
righ
t rai
l sea
t
050
0000
1000
000
1500
000
2000
000
2500
000
3000
000
Load
cyc
les
(LC
)
rail
head
at u
pper
load
rail
head
at l
ower
load
rail
foot
at u
pper
load
rail
foot
at l
ower
load
stat
ic lo
ad a
fter f
atig
ue te
st
020
4060
8010
012
014
0
Load
[kN
]
rail
head
rail
foot
Am
plitu
de o
f osc
illat
ion
Per
man
ent d
efle
ctio
n of
rail
head
afte
r dis
char
ge (P
= 0
kN):
0,
02 m
m
Per
man
ent d
efle
ctio
n of
rail
head
afte
r dis
char
ge (P
=
0kN
): 0
,42
mm
Per
man
ent d
efle
ctio
n of
rail
foot
afte
r dis
char
ge (P
= 0
kN):
0,
01 m
m
Per
man
ent d
efle
ctio
n of
rail
foot
afte
r dis
char
ge (P
= 0
kN):
0,
23 m
m
Am
plitu
de o
f osc
illat
ion
-
Appendix 2 d
Report 2466
stat
ic lo
ad b
efor
e fa
tigue
test
01234
020
4060
8010
012
014
0
Load
(kN
)
Vertical Displacement (mm)
rail
foot
fiel
dsid
e
rail
foot
in-s
ide
Fat
igue
test
at a
mbi
ent t
empe
ratu
reon
righ
t rai
l sea
t
050
0000
1000
000
1500
000
2000
000
2500
000
3000
000
Load
cyc
les
(LC
)
rail
foot
fiel
dsid
e at
upp
er lo
adra
il fo
ot fi
elds
ide
at lo
wer
load
rail
foot
in-s
ide
at u
pper
load
rail
foot
in-s
ide
at lo
wer
load
stat
ic lo
ad a
fter f
atig
ue te
st
020
4060
8010
012
014
0
Load
(kN
)
rail
foot
fiel
dsid
e
rail
foot
in-s
ide
Am
plitu
de o
f osc
illat
ion
Per
man
ent d
ispl
acem
ent o
n fie
ldsi
de a
fter d
isch
arge
(P =
0kN
):
0,18
mm
Per
man
ent d
ispl
acem
ent o
n fie
ldsi
de a
fter d
isch
arge
(P =
0kN
):
0,0
2 m
m
Per
man
ent d
ispl
acem
ent o
n in
-sid
e af
ter d
isch
arge
(P =
0kN
):
0,01
mm
Per
man
ent d
ispl
acem
ent o
n in
-sid
e af
ter d
isch
arge
(P =
0kN
):
0,08
mm
Am
plitu
de o
f osc
illat
ion
-
Appendix 3 aReport 2466
stat
ic lo
ad b
efor
e fa
tigue
test
0123456
020
4060
8010
012
014
0
Load
[kN
]
Horizontal deflection [mm]ra
il he
adra
il fo
ot
Fat
igue
test
at t
empe
ratu
re T
= +
48°C
on le
ft ra
il se
at
030
0000
6000
0090
0000
1200
000
Load
cyc
les
(LC
)
rail
head
at u
pper
load
rail
head
at l
ower
load
rail
foot
at u
pper
load
rail
foot
at l
ower
load
stat
ic lo
ad a
fter f
atig
ue te
st
020
4060
8010
012
014
0
Load
[kN
]
rail
head
rail
foot
Am
plitu
de o
f osc
illat
ion
Per
man
ent d
efle
ctio
n of
rail
head
afte
r dis
char
ge (P
= 0
kN):
0,
11 m
m
Per
man
ent d
efle
ctio
n of
rail
head
afte
r dis
char
ge (P
=
0kN
): 0
,48
mm
Per
man
ent d
efle
ctio
n of
rail
foot
afte
r dis
char
ge (P
= 0
kN):
0,
05 m
m
Per
man
ent d
efle
ctio
n of
rail
foot
afte
r dis
char
ge (P
= 0
kN):
0,
20 m
m
Am
plitu
de o
f osc
illat
ion
-
Appendix 3 b
Report 2466
stat
ic lo
ad b
efor
e fa
tigue
test
01234
020
4060
8010
012
014
0
Load
(kN
)
Vertical Displacement (mm)
rail
foot
fiel
dsid
e
rail
foot
in-s
ide
Fat
igue
test
at t
empe
ratu
re T
= +
48°C
on le
ft ra
il se
at
030
0000
6000
0090
0000
1200
000
Load
cyc
les
(LC
)
rail
foot
fiel
dsid
e at
upp
er lo
adra
il fo
ot fi
elds
ide
at lo
wer
load
rail
foot
in-s
ide
at u
pper
load
rail
foot
in-s
ide
at lo
wer
load
stat
ic lo
ad a
fter f
atig
ue te
st
020
4060
8010
012
014
0
Load
(kN
)
rail
foot
fiel
dsid
e
rail
foot
in-s
ide
Am
plitu
de o
f osc
illat
ion
Per
man
ent d
ispl
acem
ent o
n fie
ldsi
de a
fter d
isch
arge
(P =
0kN
):
0,30
mm
Per
man
ent d
ispl
acem
ent o
n fie
ldsi
de a
fter d
isch
arge
(P =
0kN
):
0,0
7 m
m
Per
man
ent d
ispl
acem
ent o
n in
-sid
e af
ter d
isch
arge
(P =
0kN
):
0,01
mm
Per
man
ent d
ispl
acem
ent o
n in
-sid
e af
ter d
isch
arge
(P =
0kN
):
0,07
mm
Am
plitu
de o
f osc
illat
ion
-
Appendix 3 cReport 2466
stat
ic lo
ad b
efor
e fa
tigue
test
0123456
020
4060
8010
012
014
0
Load
[kN
]
Horizontal deflection [mm]ra
il he
adra
il fo
ot
Fat
igue
test
at t
empe
ratu
re T
= +
48°C
on ri
ght r
ail s
eat
030
0000
6000
0090
0000
1200
000
Load
cyc
les
(LC
)
rail
head
at u
pper
load
rail
head
at l
ower
load
rail
foot
at u
pper
load
rail
foot
at l
ower
load
stat
ic lo
ad a
fter f
atig
ue te
st
020
4060
8010
012
014
0
Load
[kN
]
rail
head
rail
foot
Am
plitu
de o
f osc
illat
ion
Per
man
ent d
efle
ctio
n of
rail
head
afte
r dis
char
ge (P
= 0
kN):
0,
06 m
m
Per
man
ent d
efle
ctio
n of
rail
head
afte
r dis
char
ge (P
=
0kN
): 0
,41
mm
Per
man
ent d
efle
ctio
n of
rail
foot
afte
r dis
char
ge (P
= 0
kN):
0,
03 m
m
Per
man
ent d
efle
ctio
n of
rail
foot
afte
r dis
char
ge (P
= 0
kN):
0,
15 m
m
Am
plitu
de o
f osc
illat
ion
-
Appendix 3 d
Report 2466
stat
ic lo
ad b
efor
e fa
tigue
test
01234
020
4060
8010
012
014
0
Load
(kN
)
Vertical Displacement (mm)
rail
foot
fiel
dsid
e
rail
foot
in-s
ide
Fat
igue
test
at t
empe
ratu
re T
= +
48°C
on ri
ght r
ail s
eat
030
0000
6000
0090
0000
1200
000
Load
cyc
les
(LC
)
rail
foot
fiel
dsid
e at
upp
er lo
adra
il fo
ot fi
elds
ide
at lo
wer
load
rail
foot
in-s
ide
at u
pper
load
rail
foot
in-s
ide
at lo
wer
load
stat
ic lo
ad a
fter f
atig
ue te
st
020
4060
8010
012
014
0
Load
(kN
)
rail
foot
fiel
dsid
e
rail
foot
in-s
ide
Am
plitu
de o
f osc
illat
ion
Per
man
ent d
ispl
acem
ent o
n fie
ldsi
de a
fter d
isch
arge
(P =
0kN
):
0,24
mm
Per
man
ent d
ispl
acem
ent o
n fie
ldsi
de a
fter d
isch
arge
(P =
0kN
):
0,0
3 m
m
Per
man
ent d
ispl
acem
ent o
n in
-sid
e af
ter d
isch
arge
(P =
0kN
):
0 m
m
Per
man
ent d
ispl
acem
ent o
n in
-sid
e af
ter d
isch
arge
(P =
0kN
):
0 m
m
Am
plitu
de o
f osc
illat
ion
-
14.08.08 12:25:59mess 1Prüfamt VWB
Datum:Bearbeiter:Firma:
KOMAT - KunstholzschwelleH2O: C=44,4 mS/mU max = 42,75 VI max = 1,1 mAR 33 = 52 kOhm
5,000
4,000
3,000
2,000
1,000
0,000
-1,000
-2,000
-3,000
-4,000
-5,000[ mA ]
1 -
Str
om,
10.0
7.08
12:
51:3
0.14
4
10.07.08 12:55:00 13:00:00 13:05:00
FFU synthetic wood sleeper14.08.08 12:21:41
mess 2
Prüfamt VWB
Datum:
Bearbeiter:
Firma:
KOMAT - KunstholzschwelleH2O: C=45,3 mS/mU max = 41,45 VI max = 0,65 mAR 33 = 87 kOhm
5,000
4,000
3,000
2,000
1,000
0,000
-1,000
-2,000
-3,000
-4,000
-5,000
[ mA ]
1 -
Str
om
, 1
1.0
7.0
8 1
1:4
8:4
7.9
41
11.07.08 11:50:00 11:55:00 12:00:00
FFU synthetic wood sleeper
14.08.08 12:29:34
mess 3
Prüfamt VWB
Datum:
Bearbeiter:
Firma:
KOMAT - KunstholzschwelleH2O: C=44,6 mS/mU max = 43,25 VI max = 0,75 mAR 33 = 77 kOhm
5,000
4,000
3,000
2,000
1,000
0,000
-1,000
-2,000
-3,000
-4,000
-5,000
[ mA ]
1 -
Str
om
, 1
2.0
7.0
8 1
1:2
0:0
0.5
82
12.07.08 11:25:00 11:30:00 11:35:00
FFU synthetic wood sleeper
simonReport No. 2466 - Appendix 4
-
Ben
ding
of s
ynth
etic
sle
eper
(no.
1)
and
woo
den
slee
per
bear
ings
cle
aran
ce: 1
,5 m
020406080100
120
140
160 0
,02,
04,
06,
08,
010
,012
,014
,016
,018
,0D
efle
ctio
n (m
m)
Load (kN)
01000
2000
3000
4000
5000
6000
7000
8000
Modulus of elasticity (N/mm²)
synt
hetic
sle
eper
woo
den
slee
per
Mod
ulus
of e
last
icity
of s
ynth
etic
sle
eper
Mod
ulus
of e
last
icity
of w
oode
n sl
eepe
r
simonReport No. 2466Appendix 5
-
Def
lect
ion
of th
e sy
nthe
tic s
leep
er (f
atig
ue te
st o
n sl
eepe
r no.
2)
020406080100
120 0
,00
2,00
4,00
6,00
8,00
10,0
012
,00
14,0
0
Def
lect
ion
(mm
)
Load (kN)
3rd
load
afte
r fat
igue
test
(2.5
Mill
ion
load
cyc
les)
simonReport No. 2466Appendix 6
-
Def
orm
atio
n in
the
fatig
ue te
st (s
leep
er n
o. 2
)
024681012
050
0000
1000
000
1500
000
2000
000
2500
000
load
cyc
les
Deflection ( mm )
Def
lect
ion
at lo
ad P
= 0
kND
efle
ctio
n at
load
P=
86 k
N
simonReport No. 2466Appendix 7
-
Ben
ding
of s
ynth
etic
sle
eper
no.
4(b
earin
gs c
lear
ance
: 0,6
m)
020406080100
120
140
160 0
,00
0,50
1,00
1,50
2,00
2,50
Def
lect
ion
(mm
)
Load (kN)
3rd
load
afte
r fat
igue
test
(2 M
illio
n LC
)
simonReport No. 2466Appendix 8
-
Compression test
in-side fieldside
Permanent deformation [mm]
measuring point 1 2 3 4 5 6 7 8 9load [kN]
100 - - - - - - - - -125 - - - - - - - - -150 - - - - - - - - -175 0,05 0,05 - - 0,05 0,05 - 0,05 -200 0,05 0,10 0,05 - 0,10 0,05 - 0,10 -225 0,05 0,15 0,15 - 0,15 0,10 - 0,10 -250 0,15 0,40 0,30 - 0,15 0,10 - 0,15 0,05275 0,60 0,60 0,50 0,05 0,15 0,10 0,05 0,15 0,05300 0,80 0,80 0,70 0,05 0,15 0,10 0,10 0,15 0,10
simonReport No. 2466Appendix 9
-
Slee
per n
o. 3
, be
arin
gs c
lear
ance
: 1,0
m, T
= a
mbi
ent t
empe
ratu
re
0255075100
125
150
175
200
225 0
,00
2,00
4,00
6,00
8,00
10,0
012
,00
Def
lect
ion
(mm
)
Load (kN)
1st l
oad
2nd
load
3rd
load
simonReport No. 2466Appendix 10
-
Slee
per N
o. 1
0, b
earin
gs c
lear
ance
: 1,0
mm
, te
mpe
ratu
re T
= -1
0°C
050100
150
200
250
02
46
810
Def
lect
ion
[mm
]
Load [kN]
1st l
oad
2nd
load
3rd
load
simonReport No. 2466Appendix 11
-
Lehrstuhl und Prüfamt für Verkehrswegebau der TUM Bericht Nr. 2466
Anhang 1.1
Dauerschwellversuch in Anlehnung an DIN EN 13230-3
simonReport No. 2466Attachment 1.1
simonRepeated load test (fatigue test) in accordance with DIN EN 13230-3
-
Lehrstuhl und Prüfamt für Verkehrswegebau der TUM Bericht Nr. 2466
Anhang 1.2 Plastische Verformungen von 0,3 – 0,7 mm an der Schwellenoberfläche nach dem Dauerschwellversuch (4,3 Mio Lastspiele)
simonReport No. 2466Attachment 1.2
simonPermanent deformation of 0.3 to 0.7 mm on the sleeper surface after fatigue test (3.0 Million + 1.28 Million load cycles).
-
Lehrstuhl und Prüfamt für Verkehrswegebau der TUM Bericht Nr. 2466
Anhang 2
Zugkraft in den Schwellenschrauben in Abhängigkeit von Andrehmoment und Zeit Ausziehversuche
simonReport No. 2466Attachment 2
simonDetermination of tensile force in the sleeper screw, depending on torque moment and time.
simonPull-out test
-
Lehrstuhl und Prüfamt für Verkehrswegebau der TUM Bericht Nr. 2466
Anhang 3.1
Der Fallbär mit spurkranzförmiger Schneide dringt „sauber“ in die Schwellenkante ein. Die Zerstörung der Schwelle ist lokal eng begrenzt (Breite der Schneide)
Durchtrennte Fasern nach dem zweiten Schlag in der Schlagprüfung I.
simonReport No. 2466Attachment 3.1
simonThe tup with a wheel-flange shaped blade penetrates into the sleeper edge in a proper way. The damage is limited to a small area near impact position.
simonCutted fibres after the second impact in derailment test I.
-
Lehrstuhl und Prüfamt für Verkehrswegebau der TUM Bericht Nr. 2466
Anhang 3.2
Infolge der Schlagprüfung II (außerhalb des Schienenstrangs, 15 cm vom Schwellenende) bricht entsprechend der Faserrichtung an der Stirnseite der Schwelle ein Keil aus.
Ausbruchkeil nach dem zweiten Schlag in der Schlagprüfung II.
simonReport No. 2466Attachment 3.2
simonBy derailment test II (impact on fieldside of the rail, 15 cm distance from sleeper front end) a wedge-shaped cutout is removed from the sleeper.
simonWedge-shaped cutout after second impact in derailment test II.
-
Lehrstuhl und Prüfamt für Verkehrswegebau der TUM Bericht Nr. 2466
Anhang 3.3
Ansicht der Schwelle S8 nach dem zweiten Schlag in Schlagprüfung I.
Ausbruchkeil nach Schlagprüfung II.
simonReport No. 2466Attachment 3.3
simonView of sleeper S8 after the second impact in derailment test I.
simonWedge-shaped cutout of sleeper S8 derailment test II.
-
Lehrstuhl und Prüfamt für Verkehrswegebau der TUM Bericht Nr. 2466
Anhang 3.4
Einkerbung an Schwelle S9 nach Schlagprüfung I.
Aufgrund der homogenen Struktur der Kunstholzschwelle liefert die Schlagprüfung sehr eindeutige und reproduzierbare Ergebnisse.
simonReport No. 2466Attachment 3.4
simonNotch in sleeper S9 after derailment test I.
simonCaused by the homogeneous structure of the synthetic sleeper the derailment test shows clear and reproducible results.
-
Lehrstuhl und Prüfamt für Verkehrswegebau der TUM Bericht Nr. 2466
Anhang 3.5
Die Kunstholzschwellen sind nach der Schlagprüfung nicht verwölbt.
simonReport No. 2466Attachment 3.5
simonThe synthetic sleepers do not show any warping after the derailment test.
-
Lehrstuhl und Prüfamt für Verkehrswegebau der TUM Bericht Nr. 2466
Anhang 4
Kunstholzschwelle Holzschwelle Statische Prüfung in Schwellenmitte
simonReport No. 2466Attachment 4
simonSynthetic wood sleeper
simonWooden sleeper
Static test in sleeper centre
-
Lehrstuhl und Prüfamt für Verkehrswegebau der TUM Bericht Nr. 2466
Anhang 5 Ermüdungsprüfung in Schwellenmite
simonReport No. 2466Attachment 5
simonFatigue test in sleeper centre
-
Lehrstuhl und Prüfamt für Verkehrswegebau der TUM Bericht Nr. 2466
Anhang 6 Ermüdungsprüfung unter dem Schienenauflager
simonReport No. 2466Attachment 6
simonFatigue test under rail seat
-
Lehrstuhl und Prüfamt für Verkehrswegebau der TUM Bericht Nr. 2466
Anhang 7 Statischer Druckversuch (s. Ziff. 2.9)
simonReport No. 2466Attachment 7
simonStatic compression test (see chapter 2.9)